Cartridge and control body of an aerosol delivery device including anti-rotation mechanism and related method

ABSTRACT

The present disclosure relates to aerosol delivery devices including a cartridge and a control body. The control body may include a coupler and the cartridge may include a base. The base may be configured to releasably engage the cartridge. Further the base and the coupler may include anti-rotation mechanisms configured to prevent rotation of the cartridge relative to the base when engaged with one another. The anti-rotation mechanisms may include alternating protrusions and recesses in some embodiments. Related methods are also provided.

FIELD OF THE DISCLOSURE

The present disclosure relates to a cartridge and a control body of anaerosol delivery device such as a smoking article, and more particularlyto a cartridge and a control body of an aerosol delivery device such asa smoking article including an anti-rotation mechanism. The smokingarticle may be configured to heat an aerosol precursor, which may bemade or derived from tobacco or otherwise incorporate tobacco, to forman inhalable substance for human consumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al., U.S. patent application Ser. No.13/432,406, filed Mar. 28, 2012, U.S. patent application Ser. No.13/536,438, filed Jun. 28, 2012, U.S. patent application Ser. No.13/602,871, filed Sep. 4, 2012, and U.S. patent application Ser. No.13/647,000, filed Oct. 8, 2012, which are incorporated herein byreference.

Certain tobacco products that have employed electrical energy to produceheat for smoke or aerosol formation, and in particular, certain productsthat have been referred to as electronic cigarette products, have beencommercially available throughout the world. Representative productsthat resemble many of the attributes of traditional types of cigarettes,cigars or pipes have been marketed as ACCORD® by Philip MorrisIncorporated; ALPHA™, JOYE 510™ and M4™ by InnoVapor LLC; CIRRUS™ andFLING™ by White Cloud Cigarettes; COHITA™, COLIBRI™, ELITE CLASSIC™,MAGNUM™, PHANTOM™ and SENSE™ by Epuffer® International Inc.; DUOPRO™,STORM™ and VAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by EgarAustralia; eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd;EONSMOKE® by Eonsmoke LLC; GREEN SMOKE® by Green Smoke Inc. USA;GREENARETTE™ by Greenarette LLC; HALLIGAN™, HENDU™, JET™, MAXXQ™, PINK™and PITBULL™ by Smoke Stik®; HEATBAR™ by Philip Morris International,Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7; LOGIC™ and THE CUBAN™ byLOGIC Technology; LUCI® by Luciano Smokes Inc.; METRO® by Nicotek, LLC;NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SS Choice LLC; PREMIUMELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPP E-MYSTICK™ by RuyanAmerica, Inc.; RED DRAGON™ by Red Dragon Products, LLC; RUYAN® by RuyanGroup (Holdings) Ltd.; SMART SMOKER® by The Smart Smoking ElectronicCigarette Company Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC and VUSE® by R. J. Reynolds Vapor Company. Yetother electrically powered aerosol delivery devices, and in particularthose devices that have been characterized as so-called electroniccigarettes, have been marketed under the tradenames BLU™; COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP® and SOUTH BEACHSMOKE™.

It would be desirable to provide an aerosol delivery device that employsheat produced by electrical energy to provide the sensations ofcigarette, cigar, or pipe smoking, that does so without combustingtobacco to any significant degree, that does so without the need of acombustion heat source, and that does so without necessarily deliveringconsiderable quantities of incomplete combustion and pyrolysis products.Further, it would be desirable to provide an aerosol delivery devicethat employs convenient releasable engagement between a control body anda cartridge thereof.

BRIEF SUMMARY OF THE DISCLOSURE

In one aspect a cartridge for an aerosol delivery device is provided.The cartridge may include a reservoir substrate configured to hold anaerosol precursor composition, an atomizer configured to atomize theaerosol precursor, and a base extending between a body end orientedtoward the reservoir substrate and the atomizer and a connector endconfigured to releasably engage a control body. The base may include ananti-rotation mechanism at the connector end configured to preventrotation of the cartridge relative to the control body when engagedtherewith.

In some embodiments the anti-rotation mechanism may include a pluralityof protrusions and a plurality of recesses alternatingly disposed aboutan inner periphery of the base. A width of each of the protrusions mayincrease from the connector end toward the body end and a width of eachof the recesses may decrease from the connector end toward the body end.The cartridge may additionally include a plurality of ribs extendingfrom the inner periphery of the base at the recesses. A radial dimensionof the inner periphery of the base may decrease from the connector endtoward the body end. The base may further include a groove extending atleast partially around the inner periphery thereof.

In an additional aspect a control body for an aerosol delivery device isprovided. The control body may include a control component, anelectrical power source, and a coupler extending between a body endoriented toward the control component and the electrical power sourceand a connector end configured to releasably engage a cartridge. Thecoupler may include an anti-rotation mechanism at the connector endconfigured to prevent rotation of the control body relative to thecartridge when engaged therewith.

In some embodiments the anti-rotation mechanism may include a pluralityof protrusions and a plurality of recesses alternatingly disposed aboutan outer periphery of the coupler. A width of each of the protrusionsmay increase from the connector end toward the body end, and a width ofeach of the recesses may decrease from the connector end toward the bodyend. A radial dimension of the outer periphery of the coupler mayincrease from the connector end toward the body end. The coupler mayadditionally include a circumferential protrusion extending at leastpartially around the outer periphery thereof.

In a further aspect an aerosol delivery device is provided. The aerosoldelivery device may include a control body. The control body may includea control component, an electrical power source, a coupler extendingbetween a body end oriented toward the control component and theelectrical power source and a connector end comprising an anti-rotationmechanism. The aerosol delivery device may additionally include acartridge. The cartridge may include a reservoir substrate configured tohold an aerosol precursor composition, an atomizer configured to atomizethe aerosol precursor, and a base extending between a body end orientedtoward the reservoir substrate and the atomizer and a connector endconfigured to releasably engage the control body. The connector end ofthe base may include an anti-rotation mechanism configured to engage theanti-rotation mechanism of the coupler of the control body to preventrotation of the cartridge relative to the control body when engagedtherewith.

In some embodiments the anti-rotation mechanism of the base may includea plurality of protrusions and a plurality of recesses alternatinglydisposed about an inner periphery thereof and the anti-rotationmechanism of the coupler may include a plurality of protrusions and aplurality of recesses alternatingly disposed about an outer peripherythereof. A width of each of the protrusions of the base and theprotrusions of the coupler may respectively increase from the connectorend toward the body end and a width of each of the recesses of the baseand the recesses of the coupler may respectively decrease from theconnector end toward the body end. The base may further include aplurality of ribs extending from the inner periphery thereof at therecesses. A radial dimension of the inner periphery of the base maydecrease from the connector end toward the body end and a radialdimension of the outer periphery of the coupler may increase from theconnector end toward the body end. The base may further include a grooveextending at least partially around the inner periphery thereof and thecoupler may additionally include a circumferential protrusion extendingat least partially around the outer periphery thereof.

In another aspect a method for forming an aerosol delivery device isprovided. The method may include providing a control body and a coupler,which may respectively include some or all of the features describedabove. Further the method may include engaging the connector end of thebase to the connector end of the coupler such that the cartridgereleasably engages the control body and the anti-rotation mechanism ofthe control body engages the anti-rotation mechanism of the cartridge tosubstantially prevent rotation of the cartridge relative to the controlbody. In some embodiments engaging the connector end of the base to theconnector end of the coupler may include engaging a plurality ofprotrusions and a plurality of recesses alternatingly disposed about aninner periphery of the base of the cartridge with a plurality ofprotrusions and a plurality of recesses alternatingly disposed about anouter periphery of the control body. In some embodiments engaging theconnector end of the base to the connector end of the coupler mayadditionally include engaging a plurality of ribs extending from theinner periphery of the base at the recesses with the protrusions of thecontrol body. Engaging the connector end of the base to the connectorend of the coupler may further include engaging a circumferentialprotrusion extending at least partially around the outer periphery ofthe coupler with a groove extending at least partially around the innerperiphery of the base.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a sectional view through an aerosol delivery devicecomprising a control body and a cartridge including an atomizeraccording to an example embodiment of the present disclosure;

FIG. 2 illustrates an exploded view of a control body of an aerosoldelivery device according to an example embodiment of the presentdisclosure;

FIG. 3 illustrates the control body of FIG. 2 in a partially assembledconfiguration with an adhesive member and an outer tube removed forclarity purposes;

FIG. 4 illustrates the control body of FIG. 2 in a partially assembledconfiguration with outer tube removed for clarity purposes;

FIG. 5 illustrates the control body of FIG. 2 in an assembledconfiguration;

FIG. 6 illustrates a partially exploded view of an aerosol deliverydevice including the control body of FIG. 2 in the assembledconfiguration and a cartridge in an exploded configuration, thecartridge comprising a base shipping plug, a base, a control componentterminal, an electronic control component, a flow tube, an atomizer, areservoir substrate, an external shell, a label, a mouthpiece, and amouthpiece shipping plug according to an example embodiment of thepresent disclosure;

FIG. 7 illustrates an enlarged exploded view of the base and the controlcomponent terminal of the cartridge of FIG. 6;

FIG. 8 illustrates an enlarged perspective view of the base and thecontrol component terminal of FIG. 6 in an assembled configuration;

FIG. 9 illustrates an enlarged perspective view of the base, the controlcomponent terminal, the electronic control component, and heaterterminals of the atomizer of FIG. 6 in an assembled configuration;

FIG. 10 illustrates an enlarged perspective view of the base, theatomizer, and the control component of FIG. 6 in an assembledconfiguration;

FIG. 11 illustrates an opposing perspective view of the assembly of FIG.10;

FIG. 12 illustrates an enlarged perspective view of the base, theatomizer, the flow tube, and the reservoir substrate of FIG. 6 in anassembled configuration;

FIG. 13 illustrates a perspective view of the base and the externalshell of FIG. 6 in an assembled configuration;

FIG. 14 illustrates a perspective view of the cartridge of FIG. 6 in anassembled configuration;

FIG. 15 illustrates a first partial perspective view of the cartridge ofFIG. 6 and a coupler for a control body according to an exampleembodiment of the present disclosure;

FIG. 16 illustrates an opposing second partial perspective view of thecartridge of FIG. 6 and the coupler of FIG. 15;

FIG. 17 illustrates a perspective view of a cartridge including a basewith an anti-rotation mechanism according to an additional exampleembodiment of the present disclosure;

FIG. 18 illustrates a perspective view of a control body including acoupler with an anti-rotation mechanism according to an additionalexample embodiment of the present disclosure;

FIG. 19 illustrates alignment of the cartridge of FIG. 17 with thecontrol body of FIG. 18;

FIG. 20 illustrates an aerosol delivery device comprising the cartridgeof FIG. 17 and the control body of FIG. 18 with a modified view throughthe aerosol delivery device illustrating the engagement of theanti-rotation mechanism of the cartridge with the anti-rotationmechanism of the connector body;

FIG. 21 illustrates a perspective view of a base with an anti-rotationmechanism according to an additional example embodiment of the presentdisclosure;

FIG. 22 illustrates a perspective view of a coupler with ananti-rotation mechanism according to an additional example embodiment ofthe present disclosure;

FIG. 23 illustrates a sectional view through the base of FIG. 21 and thecoupler of FIG. 22 in an engaged configuration;

FIG. 24 illustrates an adaptor according to an example embodiment of thepresent disclosure;

FIG. 25 illustrates a method for forming an aerosol delivery deviceaccording to an example embodiment of the present disclosure; and

FIG. 26 illustrates a cross-sectional view through a funneled mouthpieceaccording to an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural referents unless the context clearly dictates otherwise.

The present disclosure provides descriptions of aerosol delivery devicesthat use electrical energy to heat a material (preferably withoutcombusting the material to any significant degree) to form an inhalablesubstance; such articles most preferably being sufficiently compact tobe considered “hand-held” devices. In certain highly preferredembodiments, the aerosol delivery devices can be characterized assmoking articles. As used herein, the term “smoking article” is intendedto mean an article or device that provides some or all of the sensations(e.g., inhalation and exhalation rituals, types of tastes or flavors,organoleptic effects, physical feel, use rituals, visual cues such asthose provided by visible aerosol, and the like) of smoking a cigarette,cigar, or pipe, without any substantial degree of combustion of anycomponent of that article or device. As used herein, the term “smokingarticle” does not necessarily mean that, in operation, the article ordevice produces smoke in the sense of the aerosol resulting fromby-products of combustion or pyrolysis of tobacco, but rather, that thearticle or device yields vapors (including vapors within aerosols thatcan be considered to be visible aerosols that might be considered to bedescribed as smoke-like) resulting from volatilization or vaporizationof certain components of the article or device. In highly preferredembodiments, articles or devices characterized as smoking articlesincorporate tobacco and/or components derived from tobacco.

Articles or devices of the present disclosure also can be characterizedas being vapor-producing articles, aerosol delivery articles ormedicament delivery articles. Thus, such articles or devices can beadapted so as to provide one or more substances (e.g., flavors and/orpharmaceutical active ingredients) in an inhalable form or state. Forexample, inhalable substances can be substantially in the form of avapor (i.e., a substance that is in the gas phase at a temperature lowerthan its critical point). Alternatively, inhalable substances can be inthe form of an aerosol (i.e., a suspension of fine solid particles orliquid droplets in a gas). For purposes of simplicity, the term“aerosol” as used herein is meant to include vapors, gases and aerosolsof a form or type suitable for human inhalation, whether or not visible,and whether or not of a form that might be considered to be smoke-like.

In use, smoking articles of the present disclosure may be subjected tomany of the physical actions employed by an individual in using atraditional type of smoking article (e.g., a cigarette, cigar or pipethat is employed by lighting and inhaling tobacco). For example, theuser of a smoking article of the present disclosure can hold thatarticle much like a traditional type of smoking article, draw on one endof that article for inhalation of aerosol produced by that article, takepuffs at selected intervals of time, etc.

Smoking articles of the present disclosure generally include a number ofcomponents provided within an outer shell or body. The overall design ofthe outer shell or body can vary, and the format or configuration of theouter body that can define the overall size and shape of the smokingarticle can vary. Typically, an elongated body resembling the shape of acigarette or cigar can be a formed from a single, unitary shell; or theelongated body can be formed of two or more separable pieces. Forexample, a smoking article can comprise an elongated shell or body thatcan be substantially tubular in shape and, as such, resemble the shapeof a conventional cigarette or cigar. In one embodiment, all of thecomponents of the smoking article are contained within one outer body orshell. Alternatively, a smoking article can comprise two or more shellsthat are joined and are separable. For example, a smoking article canpossess at one end a control body comprising a shell containing one ormore reusable components (e.g., a rechargeable battery and variouselectronics for controlling the operation of that article), and at theother end and removably attached thereto a shell containing a disposableportion (e.g., a disposable flavor-containing cartridge). More specificformats, configurations and arrangements of components within the singleshell type of unit or within a multi-piece separable shell type of unitwill be evident in light of the further disclosure provided herein.Additionally, various smoking article designs and component arrangementscan be appreciated upon consideration of the commercially availableelectronic smoking articles, such as those representative productslisted in the background art section of the present disclosure.

Smoking articles of the present disclosure most preferably comprise somecombination of a power source (i.e., an electrical power source), atleast one control component (e.g., means for actuating, controlling,regulating and ceasing power for heat generation, such as by controllingelectrical current flow the power source to other components of thearticle), a heater or heat generation component (e.g., an electricalresistance heating element or component commonly referred to as an“atomizer”), and an aerosol precursor composition (e.g., commonly aliquid capable of yielding an aerosol upon application of sufficientheat, such as ingredients commonly referred to as “smoke juice,”“e-liquid” and “e-juice”), and a mouthend region or tip for allowingdraw upon the smoking article for aerosol inhalation (e.g., a definedair flow path through the article such that aerosol generated can bewithdrawn therefrom upon draw). Exemplary formulations for aerosolprecursor materials that may be used according to the present disclosureare described in U.S. Pat. Pub. No. 2013/0008457 to Zheng et al., thedisclosure of which is incorporated herein by reference in its entirety.

Alignment of the components within the article can vary. In specificembodiments, the aerosol precursor composition can be located near anend of the article (e.g., within a cartridge, which in certaincircumstances can be replaceable and disposable), which may be isproximal to the mouth of a user so as to maximize aerosol delivery tothe user. Other configurations, however, are not excluded. Generally,the heating element can be positioned sufficiently near the aerosolprecursor composition so that heat from the heating element canvolatilize the aerosol precursor (as well as one or more flavorants,medicaments, or the like that may likewise be provided for delivery to auser) and form an aerosol for delivery to the user. When the heatingelement heats the aerosol precursor composition, an aerosol is formed,released, or generated in a physical form suitable for inhalation by aconsumer. It should be noted that the foregoing terms are meant to beinterchangeable such that reference to release, releasing, releases, orreleased includes form or generate, forming or generating, forms orgenerates, and formed or generated. Specifically, an inhalable substanceis released in the form of a vapor or aerosol or mixture thereof.Additionally, the selection of various smoking article components can beappreciated upon consideration of the commercially available electronicsmoking articles, such as those representative products listed in thebackground art section of the present disclosure.

A smoking article incorporates a battery or other electrical powersource to provide current flow sufficient to provide variousfunctionalities to the article, such as resistive heating, powering ofcontrol systems, powering of indicators, and the like. The power sourcecan take on various embodiments. Preferably, the power source is able todeliver sufficient power to rapidly heat the heating member to providefor aerosol formation and power the article through use for the desiredduration of time. The power source preferably is sized to fitconveniently within the article so that the article can be easilyhandled; and additionally, a preferred power source is of a sufficientlylight weight to not detract from a desirable smoking experience.

One example embodiment of a smoking article 100 is provided in FIG. 1.As seen in the cross-section illustrated therein, the smoking article100 can comprise a control body 102 and a cartridge 104 that can bepermanently or detachably aligned in a functioning relationship.Although a threaded engagement is illustrated in FIG. 1, it isunderstood that further means of engagement are encompassed, such as apress-fit engagement, interference fit, a magnetic engagement, or thelike.

In specific embodiments, one or both of the control body 102 and thecartridge 104 may be referred to as being disposable or as beingreusable. For example, the control body may have a replaceable batteryor a rechargeable battery and thus may be combined with any type ofrecharging technology, including connection to a typical electricaloutlet, connection to a car charger (i.e., cigarette lighterreceptacle), and connection to a computer, such as through a universalserial bus (USB) cable.

In the exemplified embodiment, the control body 102 includes a controlcomponent 106, a flow sensor 108, and a battery 110, which can bevariably aligned, and can include a plurality of indicators 112 at adistal end 114 of an external shell 116. The indicators 112 can beprovided in varying numbers and can take on different shapes and caneven be an opening in the body (such as for release of sound when suchindicators are present).

An air intake 118 may be positioned in the external shell 116 of thecontrol body 102. A coupler 120 also is included at the proximalattachment end 122 of the control body 102 and extends into a controlbody projection 124 to allow for ease of electrical connection with anatomizer or a component thereof, such as a resistive heating element(described below) when the cartridge 104 is attached to the controlbody.

The cartridge 104 includes an external shell 126 with a mouth opening128 at a mouthend 130 thereof to allow passage of air and entrainedvapor (i.e., the components of the aerosol precursor composition in aninhalable form) from the cartridge to a consumer during draw on thesmoking article 100. The smoking article 100 may be substantiallyrod-like or substantially tubular shaped or substantially cylindricallyshaped in some embodiments.

The cartridge 104 further includes an atomizer 132 comprising aresistive heating element 134 comprising a wire coil in the illustratedembodiment and a liquid transport element 136 comprising a wick in theillustrated embodiment and configured to transport a liquid. Variousembodiments of materials configured to produce heat when electricalcurrent is applied therethrough may be employed to form the wire coil.Example materials from which the wire coil may be formed include Kanthal(FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂), molybdenum silicide(MoSi), Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂), andceramic (e.g., a positive temperature coefficient ceramic). Electricallyconductive heater terminals 138 (e.g., positive and negative terminals)at the opposing ends of the heating element 134 are configured to directcurrent flow through the heating element and configured for attachmentto the appropriate wiring or circuit (not illustrated) to form anelectrical connection of the heating element with the battery 110 whenthe cartridge 104 is connected to the control body 102. Specifically, aplug 140 may be positioned at a distal attachment end 142 of thecartridge 104. When the cartridge 104 is connected to the control body102, the plug 140 engages the coupler 120 to form an electricalconnection such that current controllably flows from the battery 110,through the coupler and plug, and to the heating element 134. Theexternal shell 126 of the cartridge 104 can continue across the distalattachment end 142 such that this end of the cartridge is substantiallyclosed with the plug 140 protruding therefrom.

A reservoir may utilize a liquid transport element to transport anaerosol precursor composition to an aerosolization zone. One suchexample is shown in FIG. 1. As seen therein, the cartridge 104 includesa reservoir layer 144 comprising layers of nonwoven fibers formed intothe shape of a tube encircling the interior of the external shell 126 ofthe cartridge, in this embodiment. An aerosol precursor composition isretained in the reservoir layer 144. Liquid components, for example, canbe sorptively retained by the reservoir layer 144. The reservoir layer144 is in fluid connection with a liquid transport element 136 (the wickin this embodiment). The liquid transport element 136 transports theaerosol precursor composition stored in the reservoir layer 144 viacapillary action to an aerosolization zone 146 of the cartridge 104. Asillustrated, the liquid transport element 136 is in direct contact withthe heating element 134 that is in the form of a metal wire coil in thisembodiment.

In use, when a user draws on the article 100, the heating element 134 isactivated (e.g., such as via a puff sensor), and the components for theaerosol precursor composition are vaporized in the aerosolization zone146. Drawing upon the mouthend 130 of the article 100 causes ambient airto enter the air intake 118 and pass through the central opening in thecoupler 120 and the central opening in the plug 140. In the cartridge104, the drawn air passes through an air passage 148 in an air passagetube 150 and combines with the formed vapor in the aerosolization zone146 to form an aerosol. The aerosol is whisked away from theaerosolization zone 146, passes through an air passage 152 in an airpassage tube 154, and out the mouth opening 128 in the mouthend 130 ofthe article 100.

It is understood that a smoking article that can be manufacturedaccording to the present disclosure can encompass a variety ofcombinations of components useful in forming an electronic smokingarticle. Reference is made for example to the smoking articles disclosedin U.S. patent application Ser. No. 13/536,438, filed Jun. 28, 2012,U.S. patent application Ser. No. 13/432,406, filed Mar. 28, 2012, U.S.patent application Ser. No. 13/602,871, filed Sep. 4, 2012, thedisclosures of which are incorporated herein by reference in theirentirety. Further to the above, representative heating elements andmaterials for use therein are described in U.S. Pat. No. 5,060,671 toCounts et al.; U.S. Pat. No. 5,093,894 to Deevi et al.; U.S. Pat. No.5,224,498 to Deevi et al.; U.S. Pat. No. 5,228,460 to Sprinkel Jr., etal.; U.S. Pat. No. 5,322,075 to Deevi et al.; U.S. Pat. No. 5,353,813 toDeevi et al.; U.S. Pat. No. 5,468,936 to Deevi et al.; U.S. Pat. No.5,498,850 to Das; U.S. Pat. No. 5,659,656 to Das; U.S. Pat. No.5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 to Hajaligol; U.S.Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No. 5,573,692 to Das et al.;and U.S. Pat. No. 5,591,368 to Fleischhauer et al., the disclosures ofwhich are incorporated herein by reference in their entireties. Further,a single-use cartridge for use with an electronic smoking article isdisclosed in U.S. patent application Ser. No. 13/603,612, filed Sep. 5,2012, which is incorporated herein by reference in its entirety.

The various components of a smoking article according to the presentdisclosure can be chosen from components described in the art andcommercially available. Examples of batteries that can be used accordingto the disclosure are described in U.S. Pat. App. Pub. No. 2010/0028766,the disclosure of which is incorporated herein by reference in itsentirety.

An exemplary mechanism that can provide puff-actuation capabilityincludes a Model 163PC01D36 silicon sensor, manufactured by theMicroSwitch division of Honeywell, Inc., Freeport, Ill. Further examplesof demand-operated electrical switches that may be employed in a heatingcircuit according to the present disclosure are described in U.S. Pat.No. 4,735,217 to Gerth et al., which is incorporated herein by referencein its entirety. Further description of current regulating circuits andother control components, including microcontrollers that can be usefulin the present smoking article, are provided in U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., and U.S. Pat. No. 7,040,314 to Nguyen et al., all of which areincorporated herein by reference in their entireties.

The aerosol precursor, which may also be referred to as an aerosolprecursor composition or a vapor precursor composition, can comprise oneor more different components. For example, the aerosol precursor caninclude a polyhydric alcohol (e.g., glycerin, propylene glycol, or amixture thereof). Representative types of further aerosol precursorcompositions are set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr.et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 toBiggs et al.; and Chemical and Biological Studies on New CigarettePrototypes that Heat Instead of Burn Tobacco, R. J. Reynolds TobaccoCompany Monograph (1988); the disclosures of which are incorporatedherein by reference.

Still further components can be utilized in the smoking article of thepresent disclosure. For example, U.S. Pat. No. 5,261,424 to Sprinkel,Jr. discloses piezoelectric sensors that can be associated with themouth-end of a device to detect user lip activity associated with takinga draw and then trigger heating; U.S. Pat. No. 5,372,148 to McCaffertyet al. discloses a puff sensor for controlling energy flow into aheating load array in response to pressure drop through a mouthpiece;U.S. Pat. No. 5,967,148 to Harris et al. discloses receptacles in asmoking device that include an identifier that detects a non-uniformityin infrared transmissivity of an inserted component and a controllerthat executes a detection routine as the component is inserted into thereceptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes adefined executable power cycle with multiple differential phases; U.S.Pat. No. 5,934,289 to Watkins et al. discloses photonic-optroniccomponents; U.S. Pat. No. 5,954,979 to Counts et al. discloses means foraltering draw resistance through a smoking device; U.S. Pat. No.6,803,545 to Blake et al. discloses specific battery configurations foruse in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al.discloses various charging systems for use with smoking devices; U.S.Pat. App. Pub. No. 2009/0320863 by Fernando et al. discloses computerinterfacing means for smoking devices to facilitate charging and allowcomputer control of the device; U.S. Pat. App. Pub. No. 2010/0163063 byFernando et al. discloses identification systems for smoking devices;and WO 2010/003480 by Flick discloses a fluid flow sensing systemindicative of a puff in an aerosol generating system; all of theforegoing disclosures being incorporated herein by reference in theirentireties. Further examples of components related to electronic aerosoldelivery articles and disclosing materials or components that may beused in the present article include U.S. Pat. No. 4,735,217 to Gerth etal.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat.No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No.6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S.Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S.Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S.Pat. No. 8,156,944 to Hon; U.S. Pat. App. Pub. Nos. 2006/0196518,2009/0126745, and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos.2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No.2010/0307518 to Wang; and WO 2010/091593 to Hon. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various embodiments, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

FIG. 2 illustrates an exploded view of a control body 200 for an aerosoldelivery device according to an example embodiment of the presentdisclosure. The components of the control body 200 are described onlybriefly below due to the description of the control body illustrated inFIG. 1 being applicable to the components of the control bodyillustrated in FIG. 2. As illustrated, the control body 200 may comprisea coupler 202, a sealing member 204, an adhesive member 206 (e.g.,KAPTON® tape), a flow sensor 220, a control component 208, a spacer 210,an electrical power source 212 (e.g., a battery), a circuit board with alight emitting diode (LED) component 222, a connector circuit 224, anouter tube 214, and an end cap 216.

The coupler 202 may include control body terminals 218 extendingtherefrom which may extend through the sealing member 204 and engage oneor both of the control component 208 and the electrical power source212. The control component 208 may be a printed circuit board includinga microcontroller. The flow sensor 220 may be coupled to the controlcomponent 208 or may be a separate element. The LED component 222 can bein communication with the control component 208 through the connectorcircuit 224 and illuminate, for example, during a user drawing on acartridge coupled to the coupler 202, as detected by the flow sensor220. The end cap 216 may be adapted to make visible the LED illuminationthereunder provided by the LED component 222.

FIGS. 3-5 illustrate the control body 202 in various states of assembly.More particularly, FIG. 3 illustrates the control body 200 with theadhesive member 206 and the outer tube 214 removed for clarity purposes.FIG. 4 illustrates the control body 200 with the outer tube 214 removedfor clarity purposes. FIG. 5 illustrates the control body in afully-assembled configuration.

FIG. 6 illustrates a partially exploded view of an aerosol deliverydevice 300 including the control body 200 of FIGS. 2-5 in the assembledconfiguration and a cartridge 400 in an exploded configuration. Asillustrated, the cartridge 400 may comprise a base shipping plug 402, abase 404, a control component terminal 406, an electronic controlcomponent 408, a flow tube 410, an atomizer 412, a reservoir substrate414, an external shell 416, a label 418, a mouthpiece 420, and amouthpiece shipping plug 422 according to an example embodiment of thepresent disclosure. Note that the various embodiments of componentsdescribed above in the cited references and/or included in commerciallyavailable aerosol delivery devices may be employed in embodiments of thecartridges described herein. Note further that some of the portions ofthe cartridge 400 illustrated in FIG. 6 are optional. In this regard, byway of example, the cartridge 400 may not include the flow tube 410, thecontrol component terminal 406, and/or the electronic control component408 in some embodiments.

In one embodiment the electronic control component 408 may comprise asingle-piece printed circuit board assembly. The electronic controlcomponent 408 may include a ceramic substrate, which may comprise about96% alumina ceramic in one embodiment. This material is inorganic,non-reactive, non-degrading, and non-porous. Use of such a ceramicmaterial may be preferable in that it may define a robust,dimensionally-stable part without requiring a separate supportingstructure. Further, such a ceramic material may allow for adhesion of acoating thereto. For example, a component side of the electronic controlcomponent 408 may comprise a chloro-substituted poly (para-xylylene)commercially available as Parylene C from Specialty Coating Systems,Inc., or any other coating or other sealant/barrier coating configuredto protect components of the circuit board from liquid and moisture. Thesealant/barrier coating may also provide the electronic controlcomponent 408 with a decreased coefficient of friction, which mayfacilitate an axial assembly process of the cartridge 400.

FIG. 7 illustrates an enlarged exploded view of the base 404 and thecontrol component terminal 406. The control component terminal 406 maydefine a clip 424 configured to engage the electronic control component408 and form an electrical connection therewith. Further, the controlcomponent terminal 406 may include one or more protrusions 426 a, 426 bconfigured to engage the base 404, for example via interference fit,such that the control component terminal 406 is retained in engagementtherewith. An end 428 of the control component terminal 406 may beconfigured to engage a control body, so as to establish an electricalconnection therewith.

As illustrated, the base 404 may define a receptacle 430 configured toreceive the control component terminal 406 therein. In this regard, asillustrated in FIG. 8, the control component terminal 406 may couple tothe base 404. For example, the control component terminal 406 may beretained in the receptacle 430 of the base 404 via interference fit, forexample due to contact between the protrusions 426 a, 426 b and thebase. The control component terminal 406 may extend through the base 404to a position at which it may form an electrical connection with thecontrol body 200 to which the cartridge 400 connects. Further, the base404 may define threads or protrusions 432 configured to engage theexternal shell 416.

As illustrated in FIG. 9, the control component terminal 406 may coupleto the electronic control component 408 such that an electricalconnection is established therebetween. Accordingly, when the cartridge400 is coupled to the control body 200, the electronic control component408 may communicate therewith through the control component terminal406. The electronic control component 408 may be configured to performone or more of a variety of functions. Further, the electronic controlcomponent 408 may be configured as purpose-specific analog and/ordigital circuitry with or without a processor, or the electronic controlcomponent may comprise hardware, software, or a combination of hardwareand software. Accordingly, any or all of the functions performed by orin conjunction with the electronic control component 408 may be embodiedin a computer-readable storage medium having computer-readable programcode portions stored therein that, in response to execution by aprocessor, cause an apparatus to at least perform or direct the recitedfunctions. In one particular instance, upon establishment ofcommunication between the electronic control component 408 and thecontrol body 200, the electronic control component may be configured toprovide an authentication code or other appropriate indicia to thecontrol body. In such instances, the control body 200 may be configuredto evaluate the authentication indicia to determine whether thecartridge 400 is authorized for use with the control body. However, theelectronic control component 408 may perform various other functions.Various examples of electronic control components and functionsperformed thereby are described in U.S. patent application Ser. No.13/647,000, filed Oct. 8, 2012, which is incorporated herein byreference in its entirety.

As further illustrated in FIG. 9, a first heater terminal 434 a and asecond heater terminal 434 b (collectively, “heater terminals 434”),which may comprise portions of the atomizer 412, may couple to a bodyend 435 of the base. Note that the base 404′ illustrated in FIGS. 9 and10 differs slightly from the embodiment of the base 404 described above.For example, the protrusions 432′ define a differing configuration thanthe protrusions 432 described above. However, the protrusions 432′ andother features of the base 404′ perform substantially the same functionin substantially the same manner. Accordingly, the base 404′ is providedfor purposes of illustrating an alternate embodiment only.

The heater terminals 434 may define a plurality of walls, which mayextend at least partially around the electronic control component 408 insome embodiments such that the electronic control component is receivedtherebetween. This configuration may allow the heater terminals 434 toprovide support to the electronic control component 408, for example bycontact therewith, such that the electronic control component issecurely retained in place. Further, the heater terminals 434 may definefirst and second tabs 436 a, 436 b (collectively, “tabs 436”). The tabs436 may be positioned at the end of the heater terminals 434 distal tothe base 404′. In some embodiments the heater terminals 434 may bestamped or otherwise formed from a sheet of a metal material. However,the heater terminals 434 may be formed in various other manners andformed from any of a variety of conductive materials.

FIG. 10 illustrates the completed atomizer 412 coupled to the base 404′via the heater terminals 434. As illustrated in FIG. 10, in addition tothe heater terminals 434, the atomizer 412 may further comprise a liquidtransport element 438 and a heating element 440. The liquid transportelement 438 and the heating element 440 may be configured in asubstantially U-shaped configuration. The liquid transport element 438,which may comprise a wick (e.g., a fiberglass wick) in some embodiments,may be either preformed in the U-shaped configuration or bent to definethis configuration. A first distal arm 442 a and a second distal arm 442b (collectively, “distal arms 442”) of the liquid transport element 438may respectively extend along the first and second heater terminals 434a, 434 b. Further a center section 442 c of the liquid transport element438 may extend between the heater terminals 434.

The liquid transport element 438 may comprise a bundle of fibers, suchas fiberglass. In some embodiments, the liquid transport element 438 maycomprise a braid of four or more fibers or yarns and thus define abraided wick. The liquid transport element 438 may be in the form of asheath/core element. In particular, the sheath of the wick may be abraided wick as described above. The core of the wick may be a bundle offibers, particularly twisted fibers. The liquid transport elementspecifically may comprise one or both of E-glass and C-glass.

The heating element 440 extends at least partially about the liquidtransport element 438 and at least partially along the length of theliquid transport element. In some embodiments the heating element mayterminate at the heater terminals 434 between which the heating elementextends. However, in the illustrated embodiment the heating element 440extends along substantially the entirety of the length of the liquidtransport element 438.

In some embodiments, the heating element 440 may comprise a wiredefining a plurality of coils wound about the liquid transport element438, as illustrated in FIG. 10. The wire may comprise a materialconfigured to produce heat when electrical current is providedtherethrough. For example, the wire may comprise Kanthal (FeCrAl),Nichrome, Molybdenum disilicide (MoSi₂), molybdenum silicide (MoSi),Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂), or ceramic(e.g., a positive temperature coefficient ceramic) in some embodiments,although various other materials may be employed in other embodiments.In some embodiments the heating element 440 may be formed by winding thewire about the liquid transport element 438 as described in U.S. patentapplication Ser. No. 13/708,381, filed Dec. 7, 2012, which isincorporated herein by reference in its entirety. However, various otherembodiments of methods may be employed to form the heating element 440,and various other embodiments of heating elements may be employed in theatomizer 208.

The tabs 436 may be configured to contact the heating element 440 suchthat an electrical connection is established therebetween. In thisregard, the tabs 436 may be configured to be positioned adjacent to theheating element 440 such that the tabs directly contact one or morecoils of the wire. Direct contact, as used herein, refers to physicalcontact between the heating element 440 and the heater terminals 434.However, direct contact, as used herein, also encompasses embodiments inwhich one or more welds couple the heating element 440 and the heaterterminals 434. A weld, as used herein, refers to a solder, flux, braze,or other material that is deposited in liquid or molten form and hardensto form a connection. For example, a laser may be directed at a backside of the tabs 436, opposite from the heating element 440, which mayweld the heating element to the tabs in order to provide for aconnection therebetween.

As further illustrated in FIG. 10, in one embodiment the heating element440 may define a variable coil spacing. The spacing of the coils may bethe smallest proximate the tabs 436, greatest at the distal arms 442,and in between the spacing of the coils at the tabs and the distal armsbetween the heater terminals 434. By decreasing the spacing between thecoils of the heating element 440 proximate the tabs 436, contacttherebetween may be improved. The spacing of the coils of the heatingelement 440 between the tabs 436 may be selected to define a desiredresistance and/or produce a desired amount of heat. Further, the spacingof the coils of the heating element 440 on the distal arms 442 of theliquid transport element 438 may be relatively large in order todecrease material costs associated with production of the heatingelement.

As noted above, the electronic control component 408 may be receivedbetween the heater terminals 434 and the distal arms 442 of the liquidtransport element 438, which extend along the heater terminals. However,a gap 444 may be provided between the electronic control component 408and the heating element 440. The gap 444 may reduce the amount of heattransferred to the electronic control component 408 from the heatingelement 440, for example by preventing direct conduction therebetween.Accordingly, the risk of damage to the electronic control component 408from exposure to heat produced by the heating element 440 may bereduced.

FIG. 11 illustrates an alternative perspective view of the assemblyillustrated in FIG. 10, with the base 404′ replaced with the base 404for purposes of illustrating use of an alternate embodiment of a base.In particular, FIG. 11 illustrates a view of a connector end 446 of thebase 404 configured to releasably engage the control body 200. Asillustrated, a central opening 448 may be defined in the base 202. Thecentral opening 448 may be configured to receive airflow therethroughfrom the control body 200 and direct the airflow toward the heatingelement 440 of the atomizer 412.

The heater terminals 434 may engage the base 404 and respectively extendto a first end 450 a and a second end 450 b (collectively, “ends 450”),which may be configured to engage the control body 200, so as toestablish an electrical connection therewith. In this regard, asillustrated in FIG. 11, the end 428 of the control component terminal406 and the ends 450 of the heater terminals 434 may be exposed at theconnector end 446 of the base 404. The end 428 of the control componentterminal 406 and the ends 450 of the heater terminals 434 may be locatedat differing positions within the base 404 such that they makeconnections with components at different locations within the controlbody, and avoid unintended contact therebetween.

In this regard, the end 428 of the control component terminal 406 andthe ends 450 of the heater terminals 434 may be located at differingradial distances from the central opening 448. In the illustratedembodiment, the end 428 of the control component terminal 406 is locatedclosest to the central opening 448, the first end 450 a of the firstheater terminal 434 a is located farthest from the central opening, andthe second end 450 b of the first heater terminal 434 b is located at aradial distance therebetween. Further, the end 428 of the controlcomponent terminal 406 and the ends 450 of the heater terminals 434 mayextend to a plurality of different depths within the base 404. In theillustrated embodiment, the end 428 of the control component terminal406 extends through the base 404 to a greatest depth, the first end 450a of the first heater terminal 434 a extends through the base to thesmallest depth, and the second end 450 b of the second heater terminal434 b extends through the base to a depth therebetween.

FIG. 12 illustrates a perspective view of the assembly of FIG. 11 afterthe reservoir substrate 414 is coupled thereto. The reservoir substrate414 may be configured to hold an aerosol precursor composition. Theaerosol precursor composition may comprise a variety of componentsincluding, by way of example, glycerin, nicotine, tobacco, tobaccoextract, and/or flavorants. Various components that may be included inthe aerosol precursor composition are described in U.S. Pat. No.7,726,320 to Robinson et al., which is incorporated herein by reference.

The reservoir substrate 414 may define a cavity 452 extendingtherethrough from a first reservoir end 454 a to a second reservoir end454 b (collectively, “reservoir ends 454”), wherein the first reservoirend is positioned proximate the base 404. In this regard, the reservoirsubstrate 414 may define a hollow tubular configuration. Note thatalthough generally described herein as defining a hollow tubularconfiguration, the reservoir substrate 414 may define other shapes andconfigurations in other embodiments. The aerosol precursor compositionmay be retained within the material defining the reservoir substrate 414itself, as opposed to within the cavity 452. This configuration mayallow for airflow through the base 404, into and through the cavity 452,and past the heating element 440.

The reservoir substrate 414 can comprise one or more of variousmaterials and can be formed in a variety of different manners. In oneembodiment the reservoir substrate 414 can be formed from a plurality ofcombined layers that can be concentric or overlapping. For example, thereservoir substrate 414 can be a continuous sheet of a material that isrolled such that the ends thereof meet along a joint 456 to form thehollow tubular configuration, or multiple layers of the material may bewrapped thereabout. In other embodiments, the reservoir substrate 414can be substantially a unitary component. For example, the reservoirsubstrate 414 can be shaped or molded so as to be a singular preformedelement in the form of a substantially hollow tube, which may besubstantially continuous in composition across the length and thicknessthereof.

The reservoir substrate 414 can be formed from a material that is rigidor semi-rigid in some embodiments, while retaining the ability to storea liquid product such as, for example, an aerosol precursor composition.In certain embodiments, the material of the reservoir substrate 414 canbe absorbent, adsorbent, or otherwise porous so as to provide theability to retain the aerosol precursor composition. As such, theaerosol precursor composition can be characterized as being coated on,adsorbed by, or absorbed in the material of the reservoir substrate 414.The reservoir substrate 414 can be positioned within the cartridge 400such that the reservoir substrate is in contact with the liquidtransport element 438. More particularly, the reservoir substrate 414can be manufactured from any material suitable for retaining the aerosolprecursor composition (e.g., through absorption, adsorption, or thelike) and allowing wicking away of the precursor composition fortransport to the heating element 440.

The material of the reservoir substrate 414 may be suitable for formingand maintaining an appropriate shape. The material of the reservoirsubstrate 414 can be heat resistant so as to retain its structuralintegrity and avoid degradation at least at a temperature proximal tothe heating temperature provided by the heating element 440. However,the reservoir substrate 414 need not be heat resistant to the fulltemperature produced by the heating element 440 due to the reservoirsubstrate being out of contact therewith. The size and strength of thereservoir substrate 414 may vary according to the features andrequirements of the cartridge 400. In particular embodiments, thereservoir substrate 414 can be manufactured from a material suitable fora high-speed, automated manufacturing process. The reservoir substrate414 may be a molded piece. According to one embodiment, the reservoircan be manufactured from a cellulose acetate tow which can be processedto form a hollow acetate tube. In particular, the reservoir may be awoven or non-woven fibrous mat comprising cellulose acetate and,optionally, a binder and/or fibers formed of a different material.

In certain embodiments, the reservoir substrate 414 can be provided in aform such that at least part of the cavity 452 is shaped and dimensionedto accommodate one or more other components of the cartridge 400. Insome embodiments, the term “shaped and dimensioned” can indicate that awall of the reservoir substrate 414 at the cavity 452 includes one ormore indentations or protrusions that cause the interior of thereservoir substrate to have a shape that is other than substantiallysmooth and continuous. In other embodiments, the hollow nature of thereservoir substrate 414 can be sufficient to allow for accommodation offurther components of the cartridge 400 without the need for formationof cavities or protrusions. Thus, the cartridge 400 can be particularlybeneficial in that the reservoir substrate 414 can be pre-formed and canhave a hollow interior defining the cavity 452 with a wall that isshaped and dimensioned to accommodate a further component of thecartridge in a mating arrangement. For example, the atomizer may definegrooves configured to receive the atomizer. This particularly canfacilitate ease of assembly of the cartridge 400 and can maximize thevolume of the reservoir substrate 414 while also providing sufficientspace for aerosol formation. However, in other embodiments the atomizermay define a substantially smooth interior surface and/or conform to theshape of the components which the atomizer contacts.

As illustrated in FIG. 12, the atomizer 412 may extend through thecavity 452 of the reservoir substrate 414 such that the heating element440 is positioned proximate the second reservoir end 454 b. Moreparticularly, the atomizer 412 may extend through the cavity 452 suchthat the heating element 440 is positioned past the second reservoir end454 b and outside of the cavity. This embodiment may reduce the heatdirectly applied by the heating element 440 to the reservoir substrate414 such that the amount of the aerosol precursor composition vaporizedby the heating element is controlled in part by the flow of the aerosolprecursor composition through the liquid transport element 438 to theheating element. Accordingly, the amount of aerosol precursorcomposition vaporized may be more precisely controlled. However, inother embodiments, it is not necessary for the atomizer to extend beyondthe second reservoir end, and the atomizer can be positioned relative tothe reservoir substrate such that the heating element is received withinthe cavity of the reservoir substrate.

As illustrated in FIGS. 6 and 12, in some embodiments the cartridge mayadditionally include a flow tube 410. As illustrated in FIG. 12, theflow tube 410 may be positioned between, and held in place by, theterminals 434. More particularly, the flow tube 410 may define first 458a and second 458 b opposing grooves (collectively, “grooves 458”). Thegrooves 458 may be sized and shaped to respectively receive one of theterminals 434 therein. In this regard, in some embodiments the flow tube410 may define a generally round outer perimeter, with the exception ofthe grooves 458. Thus, the flow tube 410 may be received inside thecavity defined through the reservoir substrate 410. Accordingly, theflow tube 410 may additionally or alternatively be held in place by thereservoir substrate 410. The flow tube 410 may also be held in place viacontact with the electronic control component 408 in some embodiments.

The flow tube 410 may be configured to direct a flow of air receivedfrom the central opening 448 (see, e.g., FIG. 11) in the base 404 to theheating element 440 of the atomizer 412. More particularly, asillustrated in FIG. 12, the flow tube 410 may define a through hole 460configured to receive air from the central opening 448 in the base 404and direct it to the heating element 440. Accordingly, the size of thethrough hole 460 may be selected to define a desired velocity of airdirected to the heating element 440. Accordingly, a desired amount ofaerosol may be delivered to the air as the air passes the heatingelement 440. For example, the through hole 460 may taper from arelatively larger diameter to a relatively smaller diameter proximatethe heating element 440. However, in other embodiments the through hole490 may define a substantially constant diameter.

In some embodiments the flow tube 410 may comprise a ceramic material.For example, the flow tube 410 may comprise 96.5% aluminum trioxide inone embodiment. This material may provide heat resistance which may bedesirable due to proximity to the heating element 440. However, the flowtube 410 may be formed from various other materials in otherembodiments.

The reservoir substrate 414 includes an exterior surface 462 that can besubstantially shaped and adapted to conform to an interior surface 464of the external shell 416 (see, FIG. 13). In this regard, the externalshell 416 may define a tubular shape with a cavity 466 extendingtherethrough sized to receive the reservoir substrate 414. For example,an inner radius of the external shell 416 may substantially correspondto, or may be slightly larger than, an outer radius of the reservoirsubstrate 414. Accordingly, the external shell 416 may be received overthe reservoir substrate 414 and coupled to the base 404, as illustratedin FIG. 13. One or more indentations 468 may engage the threads orprotrusions 432 on the base 404 such that coupling is retainedtherebetween.

As illustrated in FIG. 14, the external shell 416 may couple to themouthpiece 420 such that the cavity 466 defined by the external shell isat least partially enclosed. More particularly, in one embodiment one ormore indentations 470 may engage threads or protrusions 472 on themouthpiece 420 (see, FIG. 6) such that coupling therebetween isretained. The mouthpiece 420 defines one or more openings 474 throughwhich air mixed with aerosol produced by the atomizer 412 may bedirected when a user draws on the mouthpiece, as described in accordancewith the above-noted example embodiments of smoking articles. Themouthpiece shipping plug 422 (see, FIG. 6) may engage one or more of theopenings 474 such as a center opening 474 a prior to use of thecartridge 400 in order to prevent entry of contaminants through theopenings 474 in the mouthpiece 420.

FIGS. 15 and 16 illustrate an enlarged view of the coupler 202, whichmay comprise a portion of the control body 200, aligned with thecartridge 400. The coupler 202 may be configured to engage the base 404of the cartridge 400 and various other embodiments of cartridges asdescribed herein. As illustrated, the coupler 202 may compriseprotrusions or threads 224 that are configured to engage the outer tube214 of the control body 200 such that a mechanical connection is formedtherebetween.

The coupler 202 may define an outer periphery 226 configured to matewith an inner periphery 476 of the base 404. In one embodiment the innerperiphery 476 of the base 404 may define a radius that is substantiallyequal to, or slightly greater than, a radius of the outer periphery 226of the coupler 202. Further, the coupler 202 may define one or moreprotrusions 228 at the outer periphery 226 configured to engage one ormore recesses 478 defined at the inner periphery 476 of the base 404.However, various other embodiments of structures, shapes, and componentsmay be employed to couple the base 404 to the coupler 202. In someembodiments the connection between the base 404 of the cartridge 400 andthe coupler 202 of the control body 200 may be substantially permanent,whereas in other embodiments the connection therebetween may bereleasable such that, for example, the control body may be reused withone or more additional cartridges.

The coupler 202 may further comprise a plurality of electrical contacts230 a-c respectively configured to contact the end 428 of the controlcomponent terminal 406 and the ends 450 of the heater terminals 434. Theelectrical contacts 230 a-c may be positioned at differing radialdistances from a central opening 232 through the coupler 202 andpositioned at differing depths within the coupler. The depth and radiusof each of the electrical contacts 230 a-c is configured such that theend 428 of the control component terminal 406 and the ends 450 of theheater terminals 434 respectively come into contact therewith when thebase 404 and the coupler 202 are joined together to establish anelectrical connection therebetween. More particularly, in theillustrated embodiment, a first electrical contact 230 a defines thesmallest diameter, a third electrical contact 230 c defines the greatestdiameter, and a second electrical contact 230 b defines a diametertherebetween. Further, the electrical contacts 230 a-c are located atdiffering depths within the connector 202 relative to a connector endthereof. In the illustrated embodiment, the first electrical contact 230a is located at a greatest depth, the third electrical contract 230 c islocated at the smallest depth, and the second electrical contact 230 bis located at a depth therebetween. The first electrical contact 230 amay be configured to contact the end 428 of the control componentterminal 406, the second electrical contact 230 b may be configured tocontact the second end 450 b of the second heater terminal 434 b, andthe first end 450 a of the first heater terminal 450 a may be configuredto contact the third electrical contact 230 c.

In the illustrated embodiment the electrical contacts 230 a-c comprisecircular metal bands of varying radii positioned at differing depthswithin the coupler 202 as described above. In one embodiment the bandsmay comprise continuous round rings. In another embodiment, the bandsmay comprise a sheet of metal material that is wound into the circularconfiguration and defines a joint where the ends thereof meet. In someembodiments the joint between the ends of each band of metal materialmay be configured at opposing non-perpendicular angles relative to alongitudinal length of the metal material defining the bands. Thereby,the ends of the band may meet at a joint that does not extend parallelto a central axis extending through the coupler 202. This configurationmay be preferable in that it avoids creating a joint extending parallelto the central axis through the coupler 202, which could form a poorconnection with an end of one of the heater terminals or the controlcomponent terminal when in contact therewith. Each of the bands definesa major contact surface facing radially inwardly toward the central axisof the coupler 202. The bands defining the electrical contacts 230 a-care separated from one another by stepped surfaces of the body of thecoupler 202, which may be oriented perpendicularly to the radiallyfacing major surfaces of the electrical contacts.

When the electrical contacts 230 a-c comprise circular bands and the end428 of the control component terminal 406 and the ends 450 of the heaterterminals 434 extend to corresponding depths and radii within the base404, electrical connections between the base and the coupler 202 may beestablished regardless of the rotational orientation of the base withrespect to the coupler. Accordingly, connection between the base 404 ofthe cartridge 400 and the coupler 202 of the control body may befacilitated. The electrical contacts 230 a-c may be respectively coupledto a plurality of control body terminals 218 a-c that connect to aplurality of components within the control body 200 such as theelectrical power source 212 and the control component 208 therefor. Incontrast, existing embodiments of aerosol delivery devices may employelectrical contacts in the threads of the connectors. Such connectorsmay be subject to wear from use, due to the rotation contacttherebetween necessarily occurring when the connectors are threadedtogether.

Further, when the base 404 of the cartridge 400 and the coupler 202 ofthe control body 200 are coupled together, a fluid connection may alsobe established. In this regard, the coupler 202 may define a fluidpathway configured to receive air from an ambient environment and directthe air to the cartridge 400 when a user draws thereon. Moreparticularly, in one embodiment the coupler 202 may define a rim 234with a radially extending notch 236 defined therein. Further alongitudinally extending recessed slot 238 may extend from the notch 236to an opening 240. The opening 240 may define a cutout or a hole througha portion of the coupler in some embodiments. Thus, when the coupler 202is engaged with the end of the outer body 214 of the control body 200,the fluid pathway through the notch 236, the slot 238, and the opening240 may remain open. Air drawn through this path may then be directedthrough the central opening 232 of the coupler 202 and the centralopening 448 of the base 404 when the coupler and the base are connectedto one another. Thus, air may be directed from the control body 200through the cartridge 400 in the manner described above when a userdraws on the mouthpiece 420 of the cartridge.

Accordingly, the above-described cartridge 400 may provide benefits interms of ease of assembly and ease of attachment to the coupler 202 ofthe control body 200. In particular, with respect to the cartridge 400,assembly thereof may be simplified in that the components thereof may begenerally axially assembled. More specifically, in one embodiment thecontrol component terminal 406 may be coupled to the base 404, theelectronic control component 408 may be coupled to the control componentterminal, the heater terminals 434 may be coupled to the base, the flowtube 410 may be coupled to the heater terminals and the electroniccontrol component, the heating element 440 may be coupled to the liquidtransport element 438 and the combination thereof may be coupled to theheater terminals to form the atomizer 412, the reservoir substrate 414may be coupled to the atomizer, the external shell 416 may be coupled tothe base, and the mouthpiece 420 may be coupled to the external shell.The label 418 (see, FIG. 6) may be coupled to the external shell 416 insome embodiments. Further, the base shipping plug 402 (see, FIG. 6) maybe coupled to the inner periphery 476 of the base 404 in someembodiments to protect the base during transport and storage.

Although FIGS. 15 and 16 illustrate embodiments of a base and a couplerfor a cartridge and a control body, various other embodiments of thesecomponents may be provided. In this regard, FIG. 17 illustrates acartridge 500, which may comprise some or all of the cartridgecomponents described above, and an alternate embodiment of a base 502.The base 502 may extend between a body end 504 oriented towardcomponents of the cartridge 500 such as a reservoir substrate and anatomizer, and a connector end 506 configured to releasably engage acontrol body. The base 502 may include some of the features andcomponents described above, including, for example, the end 428 of acontrol component terminal, the end of the heater terminals 450, and thecentral opening 448 extending therethrough.

The base 502 may further comprise an anti-rotation mechanism 508 at theconnector end 506. The anti-rotation mechanism 508 may be configured toprevent rotation of the cartridge 500 relative to a control body whenengaged therewith. In contrast, some prior art embodiments of cartridgesmay rely on threaded connections to mate with corresponding controlbodies. However, the potential for cross-threading therebetween exists,which may damage one or both of the control body and the cartridge.Further, users may prefer a connection between a cartridge and a controlbody that feels substantially permanent. In this regard, theanti-rotation mechanism 508 may be employed to provide a connectionbetween the cartridge 500 and a control body that feels secure andpermanent to an end user despite the releasability thereof.Additionally, prevention of rotation may reduce wear on the electricalcontacts in the control body.

As illustrated in FIG. 17, the anti-rotation mechanism 508 may comprisea plurality of protrusions 510 and a plurality of recesses 512alternatingly disposed about an inner periphery 514 of the base 502. Asfurther illustrated in FIG. 17, a width of each of the protrusions 510may increase from the connector end 506 toward the body end 504 of thebase 502. Conversely, a width of each of the recesses 512 may decreasefrom the connector end 506 toward the body end 504 of the base 502. Thebase 502 may further comprise a plurality of ribs 516 extending from theinner periphery 514 of the base 500 at the recesses 512, the purpose ofwhich will be described below.

FIG. 18 illustrates a control body 600, which may comprise some or allof the control body components described above, and an alternateembodiment of a coupler 602. The coupler 602 may extend between a bodyend 604 oriented toward components of the control body 600 such as acontrol component and an electrical power source, and a connector end606 configured to releasably engage a cartridge. The coupler 602 mayinclude some of the features and components described above, including,for example, the electrical contacts 230 a-c, and the central opening232.

The coupler 602 may further comprise an anti-rotation mechanism 608 atthe connector end 606. The anti-rotation mechanism 608 may be configuredto prevent rotation of the control body 600 relative to a cartridge whenengaged therewith. In contrast, some prior art embodiments of controlbodies rely on threaded connections to mate with correspondingcartridges. However, as noted above, the potential for cross-threadingtherebetween exists, which may damage one or both of the control bodyand the cartridge and users may prefer a connection between a cartridgeand a control body that feels substantially permanent. In this regard,the anti-rotation mechanism 608 may be employed to provide a connectionbetween the control body 600 and a cartridge that feels secure andpermanent to an end user despite the releasability thereof, and whichmay reduce wear on electrical contacts of the coupler caused by rotationbetween the cartridge and the control body.

As illustrated in FIG. 18, the anti-rotation mechanism 608 may comprisea plurality of protrusions 610 and a plurality of recesses 612alternatingly disposed about an outer periphery 614 of the coupler 602.As further illustrated in FIG. 18, a width of each of the protrusions610 may increase from the connector end 606 toward the body end 604 ofthe coupler 602. Conversely, a width of each of the recesses 512 maydecrease from the connector end 606 toward the body end 604 of thecoupler 602.

The base 502 of the cartridge 500 illustrated in FIG. 17 may beconfigured to engage the coupler 602 of the control body 600 illustratedin FIG. 18. In this regard, FIG. 19 illustrates an alignment of the base502 and the coupler 602 which may be employed during coupling betweenthe cartridge 500 and the control body 600. As illustrated, thecartridge 500 may be axially aligned with the control body 600.

During coupling of the cartridge 500 to the control body 600, the outerperiphery 614 of the coupler 602 may engage the inner periphery 514 ofthe base 502. Accordingly, the protrusions 510 and the recesses 512 ofthe base 502 may engage the recesses 612 and the protrusions 610 of thecoupler 602. Initially, when a user axially aligns the cartridge 500 andthe control body 600, the protrusions 610 of the coupler 602 may not bealigned with the recesses 512 of the base 502 and the recesses 612 ofthe coupler may not be aligned with the protrusions 510 of the base.

As noted above, the widths of the protrusions 510, 610 may increaseextending away from the respective connector ends 506, 606. Further, thewidths of the recesses 610, 612 may decrease in width extending awayfrom the respective connector ends 506, 606. Accordingly, even ifprotrusions 512 of the base 502 initially contact the protrusions 612 ofthe coupler 602, the protrusions may deflect from one another and enterrespective recesses 512, 612.

FIG. 20 illustrates an aerosol delivery device 700 comprising thecartridge 500 and the control body 600. More particularly, FIG. 20includes a modified view through the aerosol delivery device 700illustrating the engagement of the anti-rotation mechanism 508 of thecartridge 500 with the anti-rotation mechanism 608 of the connector body600. As illustrated, in some embodiments a radial dimension of the innerperiphery 514 of the base 502 decreases from the connector end 506toward the body end 504. Conversely, a radial dimension of the outerperiphery 614 of the coupler 602 increases from the connector end 606toward the body end 604. Changes in the radial dimensions of the innerperiphery 514 of the base 502 and the outer periphery 614 of the coupler602 as described above may facilitate alignment and attachment of thecartridge 500 to the control body 600. However, in other embodiments theinner periphery 514 of the base 502 and the outer periphery 614 of thecoupler 602 may define substantially constant radial dimensionsextending from the respective connector end 506, 606 toward therespective body end 504, 604.

When brought into contact in the manner described above, the base 502 ofthe cartridge 500 may engage the coupler 602 of the control body 600 toform the aerosol delivery device 700, as illustrated in FIG. 20.Further, the anti-rotation mechanisms 508, 608 may engage one anothersuch that relative rotational motion between the cartridge 500 and thecontrol body 600 is substantially prevented. In particular, engagementbetween the edges of the protrusions 512, 612 may substantially preventrotational movement between the cartridge 500 and the control body 600.

Further, during connection of the cartridge 500 to the control body 600,tips 616 of the protrusions 610 of the coupler 602 may engage the ribs516 extending from the inner periphery 514 of the base 500 at therecesses 512. In one embodiment the ribs 516 may be wedge-shaped andextend further toward the center of the base 502 at an end thereofclosest to the body end 504 of the base. Accordingly, as the coupler 602extends into the base 502, the ribs 516 may deform due to contact withthe tips 616 of the protrusions 610 of the coupler 602. For example, inone embodiment the base 502 may be formed from a material that is softerthan a material defining the coupler 602. Alternatively or additionally,contact between the ribs 516 and the tips 616 of the protrusions 610 ofthe coupler 602 may center the control body 602 with respect to the base502. Accordingly, the ribs 516 may improve the connection between thecartridge 500 and the control body 600.

In some embodiments, as illustrated in FIGS. 17, 19, and 20, the base502 may further comprise a groove 518 extending at least partiallyaround the inner periphery 514 thereof. Additionally, the coupler 602may further comprise one or more circumferential protrusions 618extending at least partially around the outer periphery thereof. Thecircumferential protrusions 618 may engage the groove 518 in the basesuch that the base 502 is releasably engaged with the coupler 602.Accordingly, the cartridge 500 and the control body 600 may “snap” intoreleasable engagement. The cartridge 500 may be decoupled from thecontrol body 600 by grasping both the cartridge and the control body andpulling the cartridge and the control body axially away from oneanother. In contrast, use of a threaded connection, as may be employedin other embodiments of aerosol delivery devices, may requireunthreading the cartridge from the control body, which may take moretime, and the strength required to decouple the cartridge from thecontrol body may vary depending on how tight the cartridge was initiallyscrewed to the control body, resulting in an inconsistent userexperience.

Note that in other embodiments the anti-rotation mechanism of thecartridge may be positioned at an outer surface thereof. Conversely, theanti-rotation mechanism of the control body may be positioned at aninner surface thereof. Accordingly, it should be understood that theparticular embodiment of the cartridge and the control body describedherein is provided by way of example only, and various otherconfigurations may be employed.

Other embodiments of bases and couplers configured to engage one anotherthat include anti-rotation mechanisms are also provided. By way ofexample, FIGS. 21 and 22 respectively illustrate embodiments of a base802 and a coupler 902 configured to engage one another. The base 802 maycomprise a portion of a cartridge and the coupler 902 may comprise aportion of a control body as described above.

In this regard, the base 802 illustrated in FIG. 21 may comprise some orall of the components described above. The base 802 may extend between abody end 804 configured to be oriented toward other components of acartridge such as a reservoir substrate and an atomizer, and a connectorend 806 configured to releasably engage a control body. Further, thebase 802 may include a central opening 448 and a groove 518 as describedabove. Although the base 802 is illustrated in isolation, the base mayalso include a control component terminal and heater terminals extendingtherethrough when assembled with additional components of a cartridge.The base 802 may further comprise an anti-rotation mechanism 808 at theconnector end 806. The anti-rotation mechanism 808 may be configured toprevent rotation of a cartridge relative to a control body when engagedtherewith.

The coupler 902 illustrated in FIG. 22 may comprise some of thecomponents of the couplers described above, including, for example, theelectrical contacts 230 a-c, the central opening 232, and the controlbody terminals 218. The coupler 902 may extend between a body end 904configured to be oriented toward components of a control body such as acontrol component and an electrical power source, and a connector end906 configured to releasably engage a cartridge. The coupler 902 mayfurther comprise an anti-rotation mechanism 908 at the connector end906. The anti-rotation mechanism 908 may be configured to preventrotation of a control body relative to a cartridge when engagedtherewith.

More particularly, the anti-rotation mechanism 808 of the base 802 maycomprise a plurality of protrusions 810 (e.g., prongs) and the coupler902 may include a plurality of recesses 912 configured to receive theprotrusions. As illustrated, the protrusions 810 and the recesses 912may respectively at least partially surround the central openings 448,232 through the base 802 and the coupler 902. In one embodiment, asillustrated, the coupler 902 may include more recesses 912 thanprotrusions 810 defined by the base. Accordingly, the recesses 912 ofthe coupler 902 may be configured to receive the protrusions 810 of thebase in multiple rotational configurations. In another embodiment theprongs 810 and the recesses 912 may be spaced apart from one another atdiffering distances such that the base 802 and the coupler 902 are keyedto join in one or more of a limited number of defined rotationalorientations.

FIG. 23 illustrates the base 802 engaged with the coupler 902. Asillustrated, when the base 802 is engaged with the coupler 902, theprotrusions 810 may extend into the recesses 912. Thus, engagementbetween the protrusions 810 and the recesses 912 may substantiallyprevent rotation of the base 802 relative to the coupler 902.

Accordingly, FIGS. 21-23 illustrate alternate embodiments ofanti-rotation mechanisms that may be employed with embodiments ofcartridges, control bodies, and aerosol delivery devices according toembodiments of the present disclosure. However, as noted above, variousother embodiments of anti-rotation mechanisms are also provided. Forexample, the protrusions may extend from the coupler and the recessesmay be provided in the base in an alternate embodiment. Further, itshould be understood that the features and components of the variousembodiments of components described herein may be combined in a varietyof manners. Thus, the various features and components described hereinare illustrated in separate features merely for example purposes.

As briefly noted above, in some embodiments the control bodies describedherein may be rechargeable. In this regard, FIG. 24 illustrates anembodiment of an adaptor 1000. The adaptor 1000 may include a USBconnector 1002 at one end and a control body connector 1004 at anopposing end. The control body connector 1004 may be configured to matchthe shape of a base of a cartridge to which a control body is configuredto engage. Thus, when the USB connector 1002 of the adaptor 1000 isplugged into an appropriate receptacle and the control body connector1004 is plugged into a control body, the electrical power source (e.g.,a battery) of the control body may be charged.

A method for forming an aerosol delivery device is also provided. Asillustrated in FIG. 2, the method may comprise providing a control bodyat operation 1102. In some embodiments the control body may comprise acontrol component, an electrical power source, a coupler extendingbetween a body end oriented toward the control component and theelectrical power source and a connector end comprising an anti-rotationmechanism, and/or any other components as described herein. Further, themethod may include providing a cartridge at operation 1104. In someembodiments the cartridge may comprise a reservoir substrate configuredto hold an aerosol precursor composition, an atomizer configured toatomize the aerosol precursor, a base extending between a body endoriented toward the reservoir substrate and the atomizer and a connectorend comprising an anti-rotation mechanism, and/or any other componentsas described herein. Additionally, the method may include engaging theconnector end of the base to the connector end of the coupler such thatthe cartridge releasably engages the control body and the anti-rotationmechanism of the control body engages the anti-rotation mechanism of thecartridge to substantially prevent rotation of the cartridge relative tothe control body at operation 1106.

In some embodiments of the method, engaging the connector end of thebase to the connector end of the coupler at operation 1106 may compriseengaging a plurality of protrusions and a plurality of recessesalternatingly disposed about an inner periphery of the base of thecartridge with a plurality of protrusions and a plurality of recessesalternatingly disposed about an outer periphery of the control body.Engaging the connector end of the base to the connector end of thecoupler at operation 1106 may further comprise engaging a plurality ofribs extending from the inner periphery of the base at the recesses withthe protrusions of the control body. Additionally, engaging theconnector end of the base to the connector end of the coupler atoperation 1106 may further comprise engaging a circumferentialprotrusion extending at least partially around the outer periphery ofthe coupler with a groove extending at least partially around the innerperiphery of the base.

FIG. 26 illustrates a cross-sectional view through an additional exampleembodiment of a mouthpiece 1200 for a cartridge. The mouthpiece 1200 mayinclude one or more protrusions 1202 configured to engage an externalshell or outer body of a cartridge such that the mouthpiece is coupledtherewith. The mouthpiece 1200 may include one or more openings throughwhich a user may draw air mixed with aerosol produced by an atomizerwhen a user draws on the mouthpiece. In this regard, the illustratedembodiment of the mouthpiece 1200 includes a single central externalopening 1204 defining by through hole.

As illustrated, the mouthpiece 1200 defines a funnel section 1206 incommunication with the external opening 1204. The funnel section 1206may be defined by an integral interior surface of the mouthpiece 1200 insome embodiments, as illustrated. More specifically, the funnel section1206 extends from a major end 1208 to a minor end 1210, wherein theminor end defines a smaller cross-sectional area than the major end. Theminor end 1210 of the funnel section 1206 may be positioned proximatethe external opening 1204. Accordingly, air drawn through the mouthpiece1200 may enter through the major end 1208 of the funnel section 1206,travel to the minor end 1210 of the funnel section, and exit to a user'smouth through the external opening 1204. In some embodiments a lip 1212may be defined at the minor end 1210 of the funnel section 1206. The lip1212 and the funnel section 1206 are configured to improve airflowthrough a cartridge to which the mouthpiece 1200 is attached by reducingeddy currents occurring downstream of the heating element. In thisregard, although not intending to be limited by any particular theory,the lip 1212 and/or the funnel section 1206 may function as a velocitystack. Note that the mouthpiece 1200 may be employed in any of theembodiments of cartridges disclosed herein.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

The invention claimed is:
 1. An aerosol delivery device, comprising: a control body comprising: a control component; an electrical power source; and a coupler comprising a plurality of electrical contacts, the coupler extending between a body end oriented toward the control component and the electrical power source and a connector end comprising an anti-rotation mechanism; and a cartridge comprising: a reservoir substrate configured to hold an aerosol precursor composition; an atomizer configured to atomize the aerosol precursor, the atomizer comprising a plurality of heater terminals; and a base extending between a body end oriented toward the reservoir substrate and the atomizer and a connector end configured to releasably engage the control body, the heater terminals extending at least partially through the base, the connector end of the base comprising an anti-rotation mechanism, the base being configured to engage the coupler such that the anti-rotation mechanism of the base engages the anti-rotation mechanism of the coupler to prevent rotation of the cartridge relative to the control body and the heater terminals engage the electrical contacts to electrically couple the cartridge to the control; and wherein the anti-rotation mechanism of the base comprises a plurality of protrusions and a plurality of recesses alternatingly disposed about an inner periphery thereof and the anti-rotation mechanism of the coupler comprises a plurality of protrusions and a plurality of recesses alternatingly disposed about an outer periphery thereof; and wherein a width of each of the protrusions of the base and the protrusions of the coupler increases from the connector end toward the body end and a width of each of the recesses of the base and the recesses of the coupler respectively decreases from the connector end toward the body end.
 2. The aerosol delivery device of claim 1, wherein the base further comprises a plurality of ribs extending from the inner periphery thereof at the recesses.
 3. The aerosol delivery device of claim 1, wherein a radial dimension of the inner periphery of the base decreases from the connector end toward the body end and a radial dimension of the outer periphery of the coupler increases from the connector end toward the body end.
 4. The aerosol delivery device of claim 1, wherein the base further comprises a groove extending at least partially around the inner periphery thereof and the coupler further comprises a circumferential protrusion extending at least partially around the outer periphery thereof.
 5. A method for forming an aerosol delivery device, the method comprising: providing a control body comprising: a control component; an electrical power source; and a coupler comprising a plurality of electrical contacts, the coupler extending between a body end oriented toward the control component and the electrical power source and a connector end comprising an anti-rotation mechanism, the anti-rotation mechanism of the coupler comprising a plurality of protrusions and a plurality of recesses alternatingly disposed about an outer periphery thereof; and providing a cartridge comprising: a reservoir substrate configured to hold an aerosol precursor composition; an atomizer configured to atomize the aerosol precursor, the atomizer comprising a plurality of heater terminals; and a base extending between a body end oriented toward the reservoir substrate and the atomizer and a connector end comprising an anti-rotation mechanism, the heater terminals extending at least partially through the base, the anti-rotation mechanism of the base comprising a plurality of protrusions and a plurality of recesses alternatingly disposed about an inner periphery thereof; and engaging the connector end of the base to the connector end of the coupler such that the cartridge releasably engages the control body, the anti-rotation mechanism of the control body engages the anti-rotation mechanism of the cartridge to substantially prevent rotation of the cartridge relative to the control body, and the heater terminals engage the electrical contacts to electrically couple the cartridge to the control body; and wherein a width of each of the protrusions of the base and the protrusions of the coupler increases from the connector end toward the body end and a width of each of the recesses of the base and the recesses of the coupler respectively decreases from the connector end toward the body end.
 6. The method of claim 5, wherein engaging the connector end of the base to the connector end of the coupler further comprises engaging a plurality of ribs extending from the inner periphery of the base at the recesses with the protrusions of the control body.
 7. The method of claim 5, wherein engaging the connector end of the base to the connector end of the coupler further comprises engaging a circumferential protrusion extending at least partially around the outer periphery of the coupler with a groove extending at least partially around the inner periphery of the base. 